Apparatus for making abrasive coated sheet material



Marcil 12, 1957 R. vc. DlcKEY Erm. 7845695 APPARATUS FOR MAKING ABRASIVE CATED SHEET MATERIAL Filed Oct. 27, 1954 2,784,665 APPARATS Foix MAK-into ABnAsrvE COATED SHEET MATERIAL Robert C. ljic'key, Mount Clemenslirederick P. Hauck,

Detroit;and. Hugh M.` Archer,` Eesti-Ahorn, Mich., assigno'rs tolvlichigaii Abrasive Company, Detroit, Mich., a corporation of Michigan Application ocmw 27, 1954, serial No. 464.932 rtciims. (Ci. uslei) The present invention relates to the production of sheetlike material having on `atleast one of its sides a coating of adhesively-bound particulate material. More specical ly, this invention relates to the production of abrasive coated sheet material such as sandpaper `and the like.

In general, there are tw'o general methods of producing sheet material coated with adhesively-bound granular tabrasive or other type of finelydivided particulate matter. One method, which may be lreferred toas the gravi'nietric method, consists in depositing the finelyLdivided material by pouring, spreading, sprinkling, spraying, or other operation, wherein the finely-divided material falls under the influence of gravity onto the adhesive coating. The other is the propulsion method wherein air, mechanical or electrostatic means propel the finely-divided material (usually against the effect of gravity) into the adhesive coating. Both ofthese methodsfind wide use in the production of sheet-like abrasive materials such as sandpaper. The propulsion method has been found superior because it results in a more uniform deposition of the abrasive and in a greater percentage of aligned particles in the coating. The latter method, however, is more dif- `cult to controland, moreover, is 'not entirely satisfactory with certain types and sizes of abrasive grains.

For the latter and other reasons, the major proportion of sandpaper-type abrasives have been 'rn-ade by gnavimetric deposition methods. 1`hese methods', however, have notresulted in as uniform or as high va quality product as has been desired. The reasons for poorer product `quality reside in the d iiiicultines i`n applying a uniform coating of abrasive grains, in firmly embedding 'the individual grains in the adhesive make coatings, and in aligning any substantial proportion of the grains. When abrasive grains are poured, sprinkled or showered by mechanical means on the moving adhesive coating, the grains tend to agglomerate, stratify` and arrange themselves in streaks or ridges on the adhesive coating. Usually, it is only their own weight in free fall which is operative to embed a portion of the particles in the adhesive with the result that the 'grains 'are more easily removed during use. Once adhered Vto the sheet, the grains `are held with their major axes randomly disposed, and as a result, the cutting efficiency of such products has been unduly low.

lt is (a principal object of this invention, therefore, to provide a method and apparatus for the production cf coated products wherein already-deposited particles lare Ymore lirinly retained by the adhesive layer by reason of 'their beingmo're deeply embedded therein.

Another object of this invention is to improve the uniformity of fan already-deposited coating of finely-divided material.

Still `ar'iotlier object of this invention is to Vvprovide method and apparatus wherein ka substantial proportion of already-'deposited `finely-divided material can be aligned with their "major 'artes normal or substantially erect on the `sheet material.,

Still another 'object of this invention 4is the elimination and dispersion of clusters formed upon the coated sheet.

nited States Patent O y 2,784,695 Pa-eee Mair e. e??

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It is also n `object of this invention to provide a method and apparatus for accomplishing the foregoing objects and, 'in addition, for removing any excess or looselyadhered material from' the coating Without disturbing einbedd'ct cr adherdinaterial, or without damage -t the adhesive layer itself or to the sheet material.

Still other objects and advantages of the present invention will be apparent, or will become apparent in the following detailed description of the invention when taken in conjunction with the accompanying drawings, in which:

Fig. l is schematic perspective View partly in section of apparatus ot this invention, showing in particular the disposition of several sets of electrodes with relation to an abrasive-coated sheet;

Fig. 2 is a cross sectional view of one of the field 'elec trodes shown in Fig. l, the section being 'taken along the line 2;-2 of Fig. l; and

Fig. 3 is a diagram of a suitable current source for the apparatus of Fig. 1.

v In `accordance with the present invention, it has been discovered that an adhesive-coated sheet having a freshlydeposited coating offinely-divided particulate material, for Aexatnple, abrasive grains deposited by agravimetric method, can be :subjected to a changing electrostatic `field wherein the particles are charged and recharged so 4as to be mutually repulsive one to the other, thereby causing loose or imperfectly adhered or embedded material to fly about in raiidoin fashion and to fill in irnperfectly coated areas; to `cause already embedded material to be more firmly embedded; `and to la certain. extent, align embedded `paiticles due to their mutual repulsion. It has been found that for these purposes, a changing field is required, that is, an electrostatic field set up by a high alternating voltage or by a unidirectional voltage of widely pulsating or changing magnitude. It is'preferred that the changing field be implemented with a corona lischage provided by a pluiality of wires or sharp discharge points. It is believed that ihsuch a field the embedded particles are wiggled or beaten in so as to be more firmly embedded. It is also believed that the changing field more efficiently redistributes imp'efectly adhered giiain's to iill in thinly coated areas and then Wiggles them firmly inthe adhesive. Likewise, itis believed that the 'changing field tirds somewhat to `align 'closely packed side-by-side particles `due to their mutual repulsion and mechanical inter ference one with the other. An unchanging or unidirectional ld does not have this effect on an already-deposited abrasive layer.

Also in accordance with this invention, it has been discovered that if arl already-'deposited abrasive layer is first wiggled or beaten by a changing field, that a subsequent exposure, before the adhesive has jdried or reset appreciably, to yan intense vunidirectional field will more efiiciently align the embedded particles and mal/,e them stand more ere'ct in the adhesive layer. The subsequent eXppsure of an already-deposited layer of particles 'to .a unidirectinal 'field vafter 'exposure to a Ychanging 'field results i'rran abrasive sheet having a greater cutting 'eilicienlcy and 'wear resistance than is possible to obtainwith either type field atene. Not only is the `p're'per'tiim of grains aligned increased, but also the petpehdicularityiof each 4alignedgrain is inc''efsed. Also, the 'unidirectional field tends to-loosen ror -re'pel the imperfectlyadheied abrasive grains seh that they more easily `drop bit the end of the machine; v

Further, in accordance with this invention, it has been found` 'that the teficiency of the electrostatic beatereld and also of the alignment `field are markedly increased if the sheet material and/or itsgrain layer are =precondi- `tioneclV befcre` introduction to` the electrostatic` fields. '-S-trayb'r unwanted chai-ges, which are easily `picked, up, induced or generated in the sheet by passage of the sheet ayrsaess in close proximity to electrified parts of the apparatus and by rubbing or travelling over its own supporting roller system are substantial and interfere with the fields. The result of this variable electrical condition in the sheeting material is erratic operation of one or both fields, arcingover, and the like. It has been found that if the sheeting material is first brought into electrical proximity to a charged or grounded electrode before introduction to the field, these charges can be neutralized, drained off, or a consistent charge imparted to the sheet and particles. Since the sheeting material, adhesive layer and abrasive grains are generally poorly-conducting materials, it is sometimes advantageous to provide, in addition to the sheet conditioning electrode, a corona discharge device adjacent and in close proximity to the grain layer in order to more effectively condition the grains themselves.

The method and apparatus of this invention will be better understood by referring to the drawings wherein Velectrode means for carrying out these functions are demonstrated in connection with the production of sandpaper, cloth-backed abrasives or similar sheet-type abrasives. As shown in Fig. 1, a contiguous sheet 1f) of paper, cloth, etc. is brought under roll 11, then upwardly around roll 12, and horizontally between coating rollers i3 to be coated with a coating of liquid adhesive or resin. The lower roll 13 is partially submerged in the liquid adhesive contained in a trough or tank 14. From the rolls 13, the adhesive-coated sheet 15 is brought vertically to pass over conveyorroll 16 whereby its adhesive-coated surface is brought face up and conducted horizontally over left-hand conveyor roll 17 and then down under tensioning roller 18 and on to the next step in the process such as drying.

Near the right-hand end of the horizontal run of the sheet 15 an abrasive feed hopper 20, a rapidly-rotating feed roll 21 and shield or baffle 22 combine to shower a more or less uniform layer of abrasive grains on the adhesive coating. After receiving the coating of abrasive grains, the sheet 15 passes over a rod-like or roller-type electrode 23.

As shown in Fig. l, a wire 24 is disposed above the sheet 15 in the vicinity of roller 23 to effect conditioning or removal of unwanted charges on the grains and upper surface of the sheet. The roller 23 is shown connected to lead 45 so as to be at the same polarity as the lower field electrode. The wire 24 is shown connected to a terminal 24a which may be of the opposite polarity to roller 23, to ground or to the same polarity as roller 23. It is preferred to connect wire 24 to the opposite pole or to ground.

The abrasive coated sheet then is moved between a pair of field electrode assemblies 31, 32. The lower electrode assembly 31 comprises a massive support element 33 of insulating material, an electrode 34 and a cover or envelope 35 of semi-conducting material. The electrode support 33 is supported on a machine frame member 36 (Fig. 2) and serves to insulate the electrode 34 from the frame and other parts of the apparatus. The electrode 34 is shown as hollow but it also could have a core of insulating material such as wood, plastic, etc. The cover or envelope 35, as pointed out above, -is made of a suitable semiconducting material such as plastic containing a conducting or semi-conducting carbon black or other filler.

The upper electrode assembly 32 has a frame or support of insulating material including angle-shaped side members 40, a top piece 41, a core of wood 42 or other poor conductor or insulator, and a plurality of wires, straps or strips 43 wound around core 42. As shown litnore clearly in Fig. 2, the core 42 and its windings 43 'but not necessarily, have 'a triangular shapee The efii- 43 are connected to the H. V. pole 81 of the transformer of the circuit shown in Fig. 3 because the web is conductive and is connected to ground by virtue of its supporting roller system.

The lower electrode assembly 31 is provided with a safety neon glow tube which has an exciter element S1 housed in insulating support 33 and a ground wire 52. The field from electrode 34, 43 excites the tube 50 and indicates to the operator that the current is turned on.

in the electric field established between electrodes 34 and 43 the abrasive particles adhering to sheet 30 are alternately attracted and repelled toward electrode 34 if `the voltage in windings 43 is alternating, or periodically repelled towards electrode 34 if Ithe voltage in windings 43 'is of the unidirectional pulsating variety. In either case, the particles are driven deeper into the adhesive layer. At the same time, the particles are given a like charge which makes `them mutually repulsive. Those which are rmly embedded, while Ithey cannot leave the adhesive layer, can move slightly for alignment purposes. Those which are loose or imperfectly attached are periodically repelled back and forth, their mutual repulsiveness tending to spread them over the entire sheet 30 where some are driven into bare or imperfectly covered adhesive areas while the beating action firmly anchors them into 'the `adhesive and secures them against further movement. in this way, the individual grains are more firmly embedded and more uniformly distributed. Since the spaces 'between embedded grains tend to be filled by loose grains, and the grains themselves are mutually repulsive, there is a strong tendency for the embedded grains to assumea vertical position due to the wedging action of the grains entering the layer under the urging of the field.

The adhesive layer on sheet 30 is most frequently characterized as a gel since it is composed of imperfcctly set or cured resin, and the like. Heretofore, it has been proposed to effect redistribution, alignment and loosening of excess grains by means of mechanical beaters operating on the opposite side of lthe sheet. These devices stretch the sheet, introduce sheettensioning problems, vibration dampening problems, and most importantly, tend to weaken, degrade or destroy the gel-like character of the adhesive. As a result, the particles are held less firmly. The electrodes 34, 43 may be termed an electrostatic beater which operates without disturbing the adhesive gel layer. Unlike mechanical beaters, the electrostatic beater fulfills one function, which mechanical beaters are incapable of, Ithat of driving embedded grains deeper into the adhesive and aligning them. lts use, therefore, results in a greatly 4superior product.

From the electrostatic 4beater electrodes 34, 43 the abrasive-coated sheet passes over a suitably electrically connected buffer electrode and lthence between a second pair of electrode assemblies 61, 62. In Fig. l, the buffer electrode 60 removes unwanted charges from the sheet 30 and increases the intensity of the alignment field. This electrode ordinarily is not required lunder favorable operation conditions. Electrodes 61, 62 are similar in design and construction to the bottom beater electrode assembly 31 in that the corona-type electrode windings of upper electrode 32 are replaced by a plain fiat or hollow electrode 63. For `the latter reason, the parts, except those noted, are given the same identifying numerals as the corresponding elements of assembly 31. Upper electrode 63 'is connected by means of lead 64 to ground or to a source of unidirectional high voltage. Lower electrode assembly I61 is connected by means of lead 65 to ground (if electrode 62 is connected to high voltage) `or to a source of high voltage of opposite polarity to that of upper electrode 62. As a result, a unidirectional electrostatic eld of great inte nsity is established between electrode assemblies `61, 62. The embedded, redistributed and partially aligned abrasive grains `on the web or sheet 30 immediately assume a more erect position. Loose or excess grains tend to `be loosened due Ito the attractive force of the `upper elect-rode 62 so as to fall into hopper 66 placed at the end of the horizontal lrun. Because of the work exerted on the embedded grains by the electrostatic beater electrodes, the eld existent between aliment electrodes 61, 62 can more eilciently perform its principal alignment function. As a result, a more elicient v and longer-wearing abrasive sheet is obtained.

An exemplary circuit for supplying an alternating high voltage is shown in Fig. 3. The current is provided by means of a pair of power input leads 70 across which is connected a safety control box consisting of a pilot light 71 and a safety switch 72. A single pole single throw switch 73 is utilized to energize and de-energize the circuit. Two leads 74 connect with a test plug 75, a voltage regulator 76, a voltmeter 77, a fuse 78, a pair of pilot lights 79 and nally a high-voltage transformer 80. One pole of the high voltage side of transformer 80 is grounded and the second pole 81 is the high voltage terminal which is connected to corona windings 43. The supply to leads 70 may be ordinary 115 volt 60 cycle current. By varying the setting of regulator 76, control of the output voltage may easily be effected. Voltages of from 5 to 40 kilovolts or more may be utilized. With the above arrangement, the transformer 80 delivers 60 cycle high voltage. For most purposes, this frequency is satisfactory. With the ner abrasive sizes, a higher frequency is sometimes advantageous and with the larger abrasive grain sizes a lower frequency sometimes is more eticient.

What is claimed is:

l. Apparatus for the production of sheet material coated with adhesively-bound particulate matter comprising means for supporting and transporting said sheet material having a coating of particulate matter adhering to yan as-yet uncured adhesive, a pair of electrodes disposed in the path of travel of said sheet material with one said electrode located thereabove and the other therebelow, the upper of said electrodes having a number of corona discharge points opposed to and in close proximity to said particulate matter on said sheet material, means for impressing a high voltage alternating electrical charge across said electrodes, a second pair of electrodes disposed subsequent to said first-named electrodes with respect to the path of travel of said sheet material, and means for impressing unidirectional high voltage to said second set of electrodes, the changing high voltage supplied to said rst set of electrodes having a sutiicient magnitude to redistribute and embed loosely adhering particulate matter on said sheet and said unidirectional voltage supplied to said second-named electrodes being suiiicient to align embedded particulate matter and loosen imperfectly adhering particulate matter on said sheet.

2. Apparatus for the production of sheet material having a coating of adhesively-bound abrasive grains Which comprises means for supporting and transporting sheet material having said abrasive coating adhering to an asyet uncured adhesive, upper and lower electrodes dis posed in the path of travel of said sheet, said upper electrode comprising a plurality of triangular shaped corona discharge wires with their points opposed to and in close proximity to said adhered abrasive grains, a second set of electrodes located about said sheet material subsequent to said first electrodes in the path of travel thereof with said sheet material passing therebetween, means for supplying an alternating current to the irst said electrodes at a voltage suiiicient to redistribute and embed loosely-adhered abrasive grains and means for applying unidirectional high voltage to said second set of electrodes suicient to align embedded abrasive grains and loosen imperfectly adhered abrasive grains.

3. Apparatus as defined in claim 2 and further characterized in that a butler electrode is disposed, in contact with a non-coated side of said sheet material, and ahead of said first electrodes, and means for connecting said buffer electrode to the same potential as the lower electrode of the said rst electrodes.

4. Apparatus as claimed in claim 2 and further characterized in that a grounded buler electrode is disposed in contact with said sheet between said rst and said second sets of electrodes.

References Cited in the le of this patent UNITED STATES PATENTS 1,854,071 Schacht Apr. 12, 1932 2,097,233 Meston Oct. 26, 1937 2,221,338 Wintermute Nov. 12, 1940 2,328,904 Hiers Sept. 7, 1943 2,385,873 Melton Oct. 2, 1945 2,447,374 Smyser Aug. 17, 1949 2,608,176 Jenkins et al. Aug. 26, 1952 2,681,036 Ewing et al. June 15, 1954 2,686,141 Sawyer Aug. 10, 1954 

